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What Is an Industrial Sensor? Complete Guide + Types and Applications

Industrial sensors, also known as industrial detectors, are essential components used in various industries to convert physical, mechanical, or chemical parameters—such as temperature, pressure, humidity, and liquid levels—into analog or digital electrical signals. These sensors play a key role in quality control, safety assurance, and optimizing operational performance across different industrial processes.

In this guide, we’ll answer the commonly asked question, “What is an industrial sensor?” and help you get familiar with the different types of industrial sensors and their applications.

What Are the Main Applications of Industrial Sensors?

Before choosing to خرید سنسور صنعتی for your factory or automation system, it's important to first evaluate the needs of your industry. Here are 5 major industries where industrial sensors are widely used:

Food and beverage industry

Robotics and automation

Automotive manufacturing

Pharmaceutical and medical industries

Assembly and material handling sectors

Why Use Industrial Sensors? Key Benefits!

Using industrial sensors in sectors such as automotive, food processing, or pharmaceuticals brings multiple benefits:

Enhanced workplace safety

High operational accuracy

Cost savings through process optimization

Improved product quality and consistency

Reduced equipment wear and extended machine lifespan

Real-time monitoring of temperature, pressure, and humidity

Types of Industrial Sensor; Complete Overview

Industrial sensors can be broadly categorized into two main types:

1. Contact Sensors

These sensors require direct physical contact to detect objects or measure variables. Pressure Sensors is Ideal for measuring pressure in gases and liquids within open or closed systems.

Force Sensors: Measure applied force or load in various industries, especially automotive.

⚠️ Contact sensors have a shorter lifespan due to constant exposure to physical forces such as shock or impact. They are more prone to wear and failure over time.

2. Non-Contact Sensors

These sensors operate without direct contact, making them more durable and reliable in harsh environments.

Advantages of Non-Contact Sensors:

Precise conversion of physical/chemical parameters into analog or digital signals

Reliable in a wide range of industrial environments

Fast switching and response time

Noise-free operation

Long service life

Let’s explore the main types of non-contact sensors used in industry:

1. Inductive Sensors

Inductive sensors operate based on Faraday’s law of electromagnetic induction. They are commonly used to detect metal objects and measure dimensions or movement.

Applications:

Automotive: Detecting metallic parts in production lines

Metal Processing: Measuring thickness or locating parts in welding and cutting

Packaging: Identifying metal items in assembly lines

Robotics: Object detection in automated systems

Electronics: Separating and detecting metal parts

2. Capacitive Sensors

Capacitive sensors detect objects by sensing changes in capacitance. They work with conductive, non-conductive, and semi-conductive materials.

Industries That Use Capacitive Sensors:

Manufacturing: Monitoring levels, weights, and humidity

Automotive: Used in braking, suspension, and autonomous systems

Electronics: Measuring voltage, frequency, and electrical parameters

Energy and Petrochemicals: Monitoring pressure and flow

Medical: Tracking vital parameters like heart rate, oxygen levels, and more

3. Magnetic Sensors

These sensors work by detecting changes in magnetic fields and are non-contact, making them highly durable.

Who Uses Magnetic Industrial Sensors?

Electronics: Used in compasses and magnetic navigation

Automotive: Applied in braking, steering, and positioning systems

Steel and Metalworks: Monitoring welding and magnetic anomalies

Oil and Gas: Detecting faults in pipelines and equipment

Medical Imaging: MRI and other diagnostic technologies

4. Ultrasonic Sensors

Ultrasonic sensors are non-contact devices that operate using high-frequency sound waves (above the human hearing range). These sensors are used for distance measurement, presence or absence detection of objects, and level control of liquids or solids.

How Ultrasonic Sensors Work:

The sensor emits an ultrasonic pulse toward the target. After the pulse hits the object, it reflects back to the sensor. The time it takes for the echo to return is measured, and using the speed of sound, the distance to the object is calculated.

Applications of Ultrasonic Sensors:

Industrial automation (for detecting the presence of objects on production lines)

Liquid level measurement in tanks and containers

Obstacle detection in robotics and automated vehicles

Packaging and bottling systems

Advantages:

Non-contact measurement

High accuracy in detecting transparent, shiny, or irregular surfaces

Not affected by color or material of the object

Limitations:

May be affected by temperature and humidity

Less effective in environments with heavy dust or sound-absorbing materials

5. Photoelectric Sensors

Photoelectric sensors are non-contact sensors that detect the presence, absence, or distance of an object using a beam of light, usually infrared or visible red light.

How Photoelectric Sensors Work:

These sensors emit a light beam from a transmitter toward a receiver. When an object interrupts or reflects the beam, the sensor detects the change and outputs a signal. There are three common types of photoelectric sensors:

Through-Beam (Opposed Mode): Transmitter and receiver are in separate units. The sensor detects when the object blocks the light beam.

Retroreflective: Transmitter and receiver are in one housing. A reflector is placed opposite the sensor. When the object interrupts the beam between the sensor and reflector, it is detected.

Diffuse Reflective: Transmitter and receiver are in one housing. The sensor detects the light reflected back from the object itself.

Applications of Photoelectric Sensors:

Detecting small or transparent objects on conveyor belts

Counting products on a line

Position detection in packaging machinery

Safety and security systems (e.g., automatic doors)

Advantages:

Fast response time

Long sensing range (especially in through-beam type)

Reliable detection of small and fast-moving objects

Limitations:

May be affected by dirt, dust, or misalignment

Performance can vary depending on surface reflectivity and color

6. Proximity Sensors

Proximity sensors are non-contact sensors that detect the presence or absence of an object within a specific range without any physical contact. Unlike photoelectric sensors, they do not use light beams, and instead rely on electromagnetic fields or capacitive effects.

Types of Proximity Sensors:

Inductive Proximity Sensors:

Detect metallic objects.

Operate based on the electromagnetic induction principle.

Common in industrial automation for detecting machine parts or fasteners.

Capacitive Proximity Sensors:

Detect both metallic and non-metallic materials (e.g., glass, plastic, wood).

Work based on changes in capacitance caused by nearby objects.

7. Ultrasonic Proximity Sensors:

Use ultrasonic waves to detect the presence and distance of an object.

Ideal for liquid level measurement or detecting irregularly shaped objects.

Applications:

Detecting objects on conveyor belts

Position detection in robotics

Liquid level sensing (capacitive or ultrasonic)

Detecting doors opening/closing (e.g., elevators)

Advantages:

Long lifespan due to non-contact operation

Fast and reliable response

Available for a wide variety of materials

Limitations:

Each type has material or environmental constraints (e.g., inductive works only with metals)

8. Temperature Sensors

Temperature sensors are devices that measure heat to detect temperature changes and convert them into a readable output, usually electrical signals. They are widely used in industrial processes, electronics, medicine, and home appliances.

How They Work:

Different temperature sensors operate on varying principles. For example, some rely on the change in electrical resistance with temperature, while others use the voltage difference generated by two different metals.

Types of Temperature Sensors:

Thermocouples:

Made from two dissimilar metals joined at one end.

Produce a voltage that varies with temperature.

Suitable for a wide temperature range and rugged environments.

Resistance Temperature Detectors (RTDs):

Use materials (typically platinum) whose resistance increases with temperature.

Very accurate and stable but more expensive than thermocouples.

Thermistors:

Semiconductor devices whose resistance decreases (NTC) or increases (PTC) with temperature.

Cost-effective and sensitive but limited to narrower temperature ranges.

Infrared (IR) Sensors:

Measure thermal radiation emitted by an object.

Useful for non-contact temperature measurements (e.g., in moving machinery or medical thermometers).

Semiconductor Temperature Sensors (e.g., IC-based):

Output a voltage or current proportional to temperature.

Often used in consumer electronics and computing.

Applications:

HVAC systems and building climate control

Industrialzautomation and process control

Medical equipment (e.g., thermometers, incubators)

Automotive systems

Food and pharmaceutical storage monitoring

Advantages:

Wide variety to suit different applications

High accuracy and reliability (especially RTDs and thermistors)

Non-contact options available

Easy to integrate with digital systems

Disadvantages:

Some types (like RTDs) are costly

Sensitivity to environmental factors (e.g., humidity, vibration)

Calibration and maintenance may be required over time

Tanavob Store; The Best Industrial Sensor Supplier in Iran

With over two decades of experience in importing and selling various industrial sensors, Tanavob Store is considered one of the top industrial equipment suppliers in Iran. Tanavob is here to help you by providing high-quality, original foreign industrial sensors, enhancing your workplace safety and improving work quality. This store is proud to have collaborated with many national and local projects, including Domino, Kaleh, Zarr Macaroon, and more. فروشگاه سنسور صنعتی تناوب is an excellent choice for purchasing industrial sensors to meet the needs of your industries.